Transcription
REFRACTORY LININGSFOR THERMAL EQUIPMENTWWW.TEPLOTECHNADIS.CZ
2 ABOUT USThe company Teplotechna DIS, s. r. o. was founded in 1998by former employees of the state company Teplotechna PKZ(doing projects for all its subsidiaries)and Teplotechna DIZ Olomouc(realized deliveries at home and abroad).By creating a team of employees with many years of experiencein designing of linings (with specific realization and managementof people) and manually skilled and technically savvy fireclaybuilders we founded a company that was able to successfullyassert itself in the business of refractory linings for thermal units.Our employees have many years of experience in the design and implementation of refractory liningsof thermal units.CONTACTS 3 HEADQUARTERSAddressLitovelská 553/26, 779 00 Olomouc, Czech RepublicTel. 420 582 770 tewww.teplotechnadis.czID253 97 338VAT NoCZ 25397338Legal form plegal entity registered in the Commercial Registerat the Regional Court in Ostrava, Section C, Insert 18548Bank Č SOB, a. s., branch OlomoucDolní náměstí 28/29, Post Code 779 00 Olomouc, Czech RepublicLITOVELSKÁ 553/26OLOMOUCThe experienced team consists of: S ales Department, Realization Department, Lining Design Department, Employees qualified for refractory works, welding works on auxiliary structures etc.For larger projects and constructions, we are able to provide other experienced fireclay builders,carpenters and locksmiths as needed.GPS: 49 35‘35.29“N, 17 14‘57.267“EWe specialize in the supply of refractory liningsfor the following areas: production of building materials (cementand lime kilns) energy production (boilers) chemicals and petrochemicals (recuperators,heat exchangers, combustion chambers, etc.) other industrial furnaces (melting, annealing,heating furnaces, etc.).Services we provide to our customers: technical documentation and engineering, supply of materials including auxiliaryanchoring structures, installation of linings including weldingof fasteners dismantling of linings, drying of linings.At present, our company operates mainly in the Czech and European market,where it has established a steady good position. Our advantage is the high flexibilityand fast adaptation to customer requirements.Teplotechna DIS, s. r. o. is certified to ISO 9001.COMPANY MANAGEMENT:Managing DirectorIng. VLADIMÍR JANISCHTel. 420 602 752 449E-mail janisch@teplotechnadis.czProject ManagerIng. RADOMÍR JANISCHTel. 420 724 141 451E-mail radomir.janisch@teplotechnadis.czChief DesignerRADIM NEUBAUERTel. 420 606 713 315E-mail neubauer@teplotechnadis.cz
4 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS 5 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALSCEMENT KILNSWe are one of the most experienced suppliers of refractory liningsfor the cement manufacturing lines.Thanks to many years of experience gained in the construction of new cement kilns and their annual repairs,we can say that there has been a relatively large increase in the demand for quality and durability of the refractorylinings. The main reason is the increasing use of alternative fuels, which are associated with formationof chemical compounds on the basis of Cl, F and SO2, which adversely affect the service life of the conventionalrefractory lining and the steel fasteners. At present the cement plants in which we operate, burn about 30 -70%alternative fuels (TAP or bone meal), which has a negative impact on the life of the refractory linings.In cooperation with the manufacturers of firebricks and refractory concrete we responsibly recommend themost suitable type of material for the process conditions of a given cement manufacturing line. We do notprefer refractory concrete or fireclay material, so we can really choose the best quality and mutually combinematerials from different manufacturers so that the result truly meets the purpose and use of the various partsof the cement line.7485In the Cement Journal we published two articles on the topic:1.2.Proposal of suspended ceilings made of shaped fireclay bricks (published 6/2014).Proposal of monolithic lining (published 9/2015).26131GRATE COOLER2KILN HOOD3INLET CHAMBER4CALCINING CHANNEL - KKN5TERTIARY PIPELINE - TAD6CYCLONES - THE BOTTOM PART7CYCLONES - THE UPPER PART8MEAL PIPES
6 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS1. GRATE COOLER› I t is a place with substantial changes in temperatureand the linings are under mechanical stress due toabrasion. Therefore, it is necessary to select materialsthat can withstand temperature changes, alkalicorrosion and abrasion.› The most stressed part are the covers around grates.There is strong abrasion and large temperature changes.› For lining of the walls and ceiling there is used mostlyfireclay material.› Ceilings are solved by means of suspended shapedpieces made of fireclay material.› Side walls above the grate are primarily made of LCCrefractory concrete with higher resistance to abrasionand thermal shock.2. KILN HOOD›T he use of alternative fuels promotes corrosion of thehot head. For this reason, we choose fireclay materials and alkali resistant LCC refractory concrete.› Lining in the kiln hood is made mostly from fireclaymaterial.› Ceilings are solved by means of suspended shapedpieces of fireclay material.› Gates to the kiln hood are made of LCC refractoryconcrete with SiC content.› For critical points around the connection of the rotarykiln and the mouthing of the pipe TAD (if TAD pipe leads into the kiln hood) is used lining made of suitableLCC refractory concrete - most often, we choose aninstallation by casting into formwork under vibration.3. INLET CHAMBER›T here are applied linings resistant to alkaline corrosion,abrasion, build-ups formation and dynamic loads(air blasters, rotary kiln).›T his is a very articulated section, so there we choosemainly a lining of suitable refractory concrete witha higher proportion of SiC (10-25%).› I n straighter sections, instead of refractory liningswe can use pre-dried shaped bricks made of suitablerefractory concrete.4. CALCINING CHANNEL - KKNKKN consists of: Ascending part of KKN, Descending part of KKN, Vortex head.›F rom structural viewpoint calcination channel hasa circular or rectangular cross section.›T he temperature ranges 900 - 1100 C.›M ostly (from 80%) there is suitable lining from fireclaymaterial, even in the round and rectangular crosssection.› I n places like transition pieces, etc., we choose a liningfrom LCC refractory concrete, which is installed bycasting into formwork.›F or the lower part of the ascending channel we choosequality materials, due to higher temperatures, alkalinecorrosion, abrasion and formation of build-ups.›A t the bottom of KKN there is evident the pronouncedinfluence of the use of alternative fuels.› In the vortex head the material is chosen accordingto its particular shape.›T he ceiling in the vortex head can be solved by meansof suspended shaped pieces made of fireclay materialor LCC refractory concrete with silicon carbide content.› I n places where we decide to use refractory concretelining, we can replace the selected installation methodalso with gunned concrete.5. TERTIARY PIPELINE - TAD› From structural viewpoint the TAD pipe has a circularcross section.› The temperatures here range 900 - 1000 C.Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS 7 › Usually (about 90%) the most suitable lining is fromfireclay material.› In bending points we use lining from suitable refractoryconcrete, or use a pre-dried shaped bricks made ofsuitable refractory concrete.› In TAD the environment is heavily exposed to abrasiondust.› Here we choose abrasion-resistant material resistantto alkalis.› The tertiary conduit includes also a damper, whichhelps against the abrasion of the flowing clinker dustand against temperature variations. Lining of thedamper is designed as self-flowing SFC refractoryconcrete or other suitable refractory concrete.6. CYCLONES - THE BOTTOM PART› The bottom usually includes the lowermost cyclones,CIV and CV.› Contemplated temperatures in these cyclones reach800 to 900 C, in some cases the temperature canreach 1000 C.› In these cyclones we can already see a clear impactof alternative fuels on the lining.› There is chemical corrosion of linings, corrosion of hotdip steel and formation of build-ups.› We mostly chose linings made of fireclay material incombination with a suitable LCC refractory concrete, whichis installed by casting into formwork under vibration. It isa circular and conical part of the cyclones.› C eilings of cyclones are formed from suspendedfireclay shaped bricks.› For lining of ceilings, circular part and conical partthere may also be used suitable LCC refractoryconcrete that resists alkalis with the content of siliconcarbide.› All steel constructions (brackets, anchors, hinges)are made from heat-resistant stainless steel.
8 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS 9 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS7. CYCLONES - THE UPPER PART› The upper part usually includes cyclones CI, CII and CIII.› Contemplated temperatures in these cyclones range300-600 C, in the cyclone CIII it can reach even800 C.› W ith proper operation of the line, the effects ofalternative fuels shall not have impact any more.› In these areas there is in particular mechanical stresson the linings – due to abrasion.› Here, we choose linings from fireclay materials orsprayed dense and insulating refractory concretes(especially in cyclones CI and CII).› Recently there have been used insulating refractoryconcretes with higher thermal conductivity forsingle-layer lining.SELECTED REFERENCESPetersburgement(Eurocement group)TAD lining, kiln head, inlet chamber grate cooler,cement plant in Slantsyin Russia2015A B CAliacem, s. r. o.installation of a new heat exchanger linings,cement plant in HraniceCzech Republic2014CPSP Engineering, a. s.bypass linings, cementplant Saint Pierre la Court,France2015A BPSP Engineering, a. s.lining of a new heat exchanger,cement plant Lafarge Cement, Čížkovice,Czech Republic2014A B CAliacem, s. r. o.lining of a grate cooler,cement plant Cemmac in Horné Srnie,Slovakia2013A B CAliacem, s. r. o.lining of a grate cooler,Libya2013A BPSP Engineering, a. s.linings of new cement lines,cement plant in Turňa nad Bodvouin Slovakia2004A B CPSP Engineering, a. s.linings of new cement lines,cement plant Cemmac in Horné Srnie,Slovakia2000A B C8. MEAL PIPES› L ining is from LCC concrete, which is installed bycasting into formwork under vibration.› T he insulating layer is made of calcium silicateboards.› For lining of meal pipes connecting cyclone IV andV, LCC refractory concrete is used which resistsalkalis due to presence of silicon carbide.› For lining of meal pipes connecting cyclone I, II andIII, standard LCC refractory concrete is used.A documentation and engineering / B delivery of material / C mounting / D supervisingIn addition to these contracts, we are involved in repairing the lining in these cement plants: Českomoravský cement a.s., plant in MokráCement Hranice, a.s,CEMMAC, a.s. in Horne SrnieLafarge Cement a.s. in Čížkovice
10 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS 11 Teplotechna DIS – PRODUCTION OF CONSTRUCTION MATERIALS2. LIME KILNS FOR THE MANUFACTURING OF LIMELIME KILNS1. LIME KILNS IN SUGAR REFINERIESWe have extensive experience with lining of lime kilns in sugar refineries, which were plenty in the regionof Haná. The most widely used are the simple shaft lime kilns with circular cross section and internalheating, where limestone is burned with the aid of coke. The lime kilns are continuous type furnaces,so the risk of thermal shock is minimal.Maertz type lime kilnsand other shaft furnacesLine for the production of lime with a rotary kiln(PSP Engineering design)Our employees have participated in the constructionof refractory lining for Maertz type lime shaft kilnin lime kilns Varin (Dolvap, s.r.o.) and Čertovy schody(Lhoist Group) and the installation of a lime shaftkiln in Kotouč Štramberk, s.r.o.The line consists of a pre-calciner, rotary kiln, hothead and a shaft cooler, the system of lining is similarto the one of cement kilns. We are able to offerdocumentation for the lining, material supply andinstallation of lining in the lime lines.Teplotechna DIS, s.r.o. performs either complete or partial replacement of magnesite and refractory liningand also lining repairs by gunning (gunned concrete) a layer of a suitable refractory concrete.Condition of the lining greatly affects the way of operation of the lime plant and dispensing the mixture of cokeand limestone. Due to improper stratification of coke in the mixture there occurs local overburning of lining.SELECTED REFERENCESMoravskoslezské cukrovary, a. s.,sugar refinery in Hrušovanynad Jevišovkounew lining of a lime kiln no. 12000A B CSlovenské cukrovary, a. s.,sugar refinery in Sereďpartial repair of the magnesite housingand spraying of the refractory coating2015A B CLitovelská cukrovarna, a. s.,partial repair of fireclay casing andspraying of a refractory concrete coating2013A B CCukrovar Vrbátky, a. s.partial repair of fireclay casing andspraying of a refractory concrete layer2015A B CHanácká potravinářskáspolečnost, s. r. o.,sugar refinery in Prosenicepartial repair of fireclay casing andspraying of a refractory concrete layer2014A B CCarmeuse Czech Republic, s. r. o.,plant in Mokránew lining of the kiln head2012A B CVUC, a. s.lining of the upper part of the lime kiln anda new cap for the sugar refinery Agrana2008A B CPSP Engineering, a. s.new lining for a lime kiln in Lithuania2007A B CA documentation and engineering / B delivery of material / C mounting / D supervisingDepending from the success in annual tenderswe carry out repairs in these sugar mills: Sugar refinery in LitovelSugar refinery in VrbátkySugar refinery in ProseniceS
or LCC refractory concrete with silicon carbide content. › In places where we decide to use refractory concrete lining, we can replace the selected installation method also with gunned concrete. 5. TERTIARY PIPELINE - TAD › From structural viewpoint the TAD pipe has a circular cross section. › The temperatures here range 900 - 1000 C.
